Ceramic materials are key components in making sure furnaces retain uniform heating throughout each...
Product Solution: Isofrax® 1400 Modules
Industry: Ceramic – Refractory Ware
Application: Ceramic Kiln Lining
Business Challenge
Our client is a renowned supplier of the full range of refractory and thermal insulation materials for all of the major industrial sectors that rely on thermal based processes. They embrace the technical challenges that form the core of these critical applications. They have gained over 30 years’ experience in developing solutions that include the design of refractory and fibre based linings, the production of the most complex special shapes, installation work, the supervision of the installation of the lining and in providing after sales assistance. They select and propose the highest quality products for their clients. They combine this with comprehensive technical assistance that guarantees that the best refractory lining and thermal efficient solution can be provided. The heating and cooling cycles in the production of special fired refractory shapes requires critical firing and consistent thermal performance from the kiln.
Application
A high temperature ceramic kiln used for the firing of special refractory shapes was in need of a refurbishment. The client was looking for a replacement low thermal mass lining. Unifrax fiber was their natural choice. An engineered solution was developed, taking into account the problems that they had experienced with the previous lining. This is a high temperature application operating at 1300 °C. The operating conditions required a unique approach from Unifrax. The design incorporated several product grades and forms for various sections of the kiln to provide the optimum performance in service.
Solution
For the end and side walls of the kiln Isofrax 1400 Modules were chosen as the ideal product due to their thermal performance and temperature resistance. The chemistry for Isofrax 1400 also passes requirements for health and safety due to unique LBP (Low Bio-persistent) qualities of the chemistry.
The kiln construction was a metal framework and a mesh casing. After removal of the existing lining the new stainless steel studs were welded in place. Edge stack modules with 12" thick x 10# density. For the roof section and door the module grade was Saffil M-Fil grade 12" x 8#. A back-up layer of Insulfrax SF Blanket (aluminium foil faced) x 8# was installed throughout the internal area of the kiln. All modules were installed in a uni-directional pattern. For the walls a folded blanket batten strip of Isofrax 1400 Blanket was installed between module rows.
Upon completion of the module installation a 5 – 10mm thickness of Silplate Mass S (a protective coating) was applied to the whole of the wall lining surface. This was gunned in place using the air driven Fraxpump.
Photo 4 - Lining After Application of Silplate Mass S |
Photo 5 - Fraxpump Equipment |
Customer Advantages
Both the Sales and Application Engineer worked closely together on this project with the client to develop an Engineering solution. This was accomplished by providing engineered drawings and on-site support for the successful installation of the Isofrax 1400 Module lining, as well as the Saffil and Silplate Mass S.
The benefits included a thermally efficient lining with enhanced operating productivity. The installation guidelines allowed simple installation in the shortest time possible. As a Non-classified solution, this installation was carried out within company Health and Safety regulations.
